Sharps disposal container

ABSTRACT

A sharps container apparatus comprising a container including a door manually movable between a closed position and an open position, and a rubber band for biasing the door toward the closed position, the container being completely closed when the door is in the closed position, a bracket adapted to be securely mounted on a wall, and interengaging projections and slots on the bracket and on the container for securing the container to the bracket.

RELATED APPLICATION

This is a divisional of application Ser. No. 08/045,830 filed Apr. 9,1993, now U.S. Pat. No. 5,413,243, which is a continuation of Ser. No.07/651,294 filed Feb. 5, 1991, now abandoned, which is a continuation ofapplication Ser. No. 07/309,208 filed Dec. 20, 1988, now abandoned,which is a continuation-in-part of application Ser. No. 07/040,430,filed Apr. 30, 1987, issued as U.S. Pat. No. 4,736,860 on Apr. 12, 1988and entitled "SHARPS DISPOSAL CONTAINER".

BACKGROUND OF THE INVENTION

The invention relates to sharps disposal apparatus, i.e., apparatus usedin hospitals for containing sharp items such as used hypodermic needles.

Various government agencies recommend or require that hospitals providea sharps disposal unit in each patient room. These units are intended toprevent used sharp items from causing injury to or infecting patientsand hospital personnel and to prevent patients from stealing theseitems. Theft of used hypodermic needles (typically by intravenous drugusers) is becoming a matter of great concern because of the rapid spreadof AIDS. On the other hand, there is currently an emphasis in hospitalsto make patient rooms more comfortable by improving their appearance andminimizing the amount of medical equipment therein.

Furthermore, government regulations require that some terminal treatmentbe applied to contaminated waste prior to disposal. In the case ofsharps disposal units, this generally means incineration or steamsterilization.

SUMMARY OF THE INVENTION

The invention provides a sharps disposal unit that is easy tomanufacture and assemble, is easily removed by authorized personnel butresists unauthorized tampering, is easy to use, has a pleasantappearance, and can be steam sterilized.

More particularly, the invention provides an apparatus comprising acontainer including a base and a cover connected to the base by anintegral hinge. The cover is originally open so that the container canbe nested with another container for shipping. The base and the coverinclude permanently interlocking means so that the container can bepermanently closed after shipping.

The cover, which forms the upper portion of the container, includes adoor which is manually movable between a closed position and an openposition and which is biased toward the closed position. The containeris completely closed when the door is in the closed position.Preferably, the door can be opened with one hand holding an object,e.g., a used hypodermic syringe, to be placed in the container.

Additionally, the apparatus comprises means for preventing removal ofthe contents of the container when the door is in the open position.Thus, the door can be opened to permit insertion of additional contents,but not to remove the present contents. Furthermore, the apparatuscomprises means for selectively and permanently locking the door in theclosed position when the container is full. In the preferred embodiment,this means includes a pin which is inserted through the container andinto the door to prevent movement of the door relative to the container.

The apparatus further comprises a bracket that can be securely mountedon a wall by screws or other suitable means. The sides of the bracketextend generally vertically and slide into complementary slots formed onthe back of the container. To attach the container to the bracket, thecontainer is located above the bracket with the sides of the bracketaligned with the slots and is then lowered onto the bracket so that thesides of the bracket slide into the slots.

The bracket and container also include means for preventing unauthorizedremoval of the container from the bracket and for permitting authorizedremoval of the container from the bracket. Preferably, this preventingmeans includes, on the bracket, a resilient projection which is normallyin a securing position and which is deflectible to a releasing position.The projection is in the securing position and extends into a recess inthe container when the container is secured on the bracket. Thepreventing means also includes key means for deflecting the projectionfrom the securing position to the releasing position. When the containeris secured on the bracket, the projection prevents removal of thecontainer from the bracket unless the key means is used to deflect theprojection to the releasing position.

Preferably, the container, the bracket, and the door are all molded inone piece by conventional plastic injection methods. Each piece ismolded with a simple two-piece mold that requires no cores or movingparts. The pieces snap together so that no tools are required forassembly. Also, the pieces are made of a plastic that is suitable forsteam sterilization.

Other features and advantages of the invention will become apparent tothose skilled in the art upon review of the following detaileddescription and claims.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an apparatus embodying the invention.

FIG. 2 is a vertical cross sectional view of the apparatus with the doorand cover closed.

FIG. 3 is a partial view similar to FIG. 2 with the cover open and thedoor closed.

FIG. 4 is a partial view similar to FIG. 2 with the cover closed and thedoor open.

FIG. 5 is a cross-sectional view taken along line 5--5 in FIG. 2.

FIG. 6 is a front elevational view of the bracket.

FIG. 7 is a rear elevational view of the container.

FIG. 8 is a partial view similar to FIG. 2 showing the key releasing thecontainer.

FIG. 9 is a perspective view of the key.

FIG. 10 is a view taken along line 10--10 in FIG. 2.

FIG. 11 is a view taken along line 11--11 in FIG. 10.

FIG. 12 is a view taken along line 12--12 in FIG. 10.

FIG. 13 is an enlarged view of the upper left-hand portion of FIG. 10with the pin in the locking position.

FIG. 14 is a top view of a container of an alternative embodiment of theinvention.

FIG. 15 is a view taken along line 15--15 in FIG. 14.

FIG. 16 is a view similar to FIG. 15 with the door locked in the closedposition.

FIG. 17 is an enlarged view of a portion of FIG. 16.

FIG. 18 is a partial vertical, cross-sectional view of a secondalternative embodiment of the invention with the cover disconnected fromthe base and without the door.

FIG. 19 is a view similar to FIG. 18 with the cover partially connectedto the base.

FIG. 20 is a view similar to FIG. 18 with the cover fully connected tothe base.

FIG. 21 is an enlarged view of a portion of FIG. 20.

Before one embodiment of the invention is explained in detail, it is tobe understood that the invention is not limited in its application tothe details of construction and the arrangements of components set forthin the following description or illustrated in the drawings. Theinvention is capable of other embodiments and of being practiced orbeing carried out in various ways. Also, it is to be understood that thephraseology and terminology used herein is for the purpose ofdescription and should not be regarded as limiting.

DESCRIPTION OF THE PREFERRED EMBODIMENT

An apparatus 10 embodying the invention is illustrated in the drawings.As shown in FIGS. 1 and 2, the apparatus 10 comprises a container 12including a base 14, and a cover 16 connected to the base 14 by anintegral hinge 18. The cover 16 is movable relative to the base 14between an open position (FIG. 3) and a closed position (FIGS. 1, 2 and4). In order to save space for shipping, the container 12 can be nestedwith other containers when the cover 16 is in the open position.

The container 12 further includes means for selectively and permanentlysecuring the cover 16 in the closed position, so that the cover 16cannot be opened once it is closed. While various suitable means can beemployed, in the preferred embodiment, this means includes integral,non-reversible snap fasteners 20 on the base 14 and on the cover 16.

The container 12 further includes a door 22 which is located adjacent anopening 24 in the cover 16, which is manually movable between a closedposition (FIGS. 1, 2, and 3) and an open position (FIG. 4), and which isbiased toward the closed position. The container 12 is completely closedwhen the cover 16 is in its closed position and the door 22 is in itsclosed position. While various suitable means can be used for biasingthe door 22 toward the closed position, in the illustrated construction,such means includes a rubber band 26 connected between the cover 16 andthe door 22.

More particularly, the door 22 has thereon a semi-cylindrical portion 23having as its axis of curvature the axis of rotation of the door 22. Theportion 23 has therein a circumferentially extending recess 25 and hasthereon, at one end of the recess 25, a projection 27. The cover 16 hasthereon a projection 29, and the rubber band 26 is wound around thesemi-cylindrical portion 23, in the recess 25, with one end of therubber band 26 hooked on the projection 29 and with the opposite end ofthe rubber band 26 hooked on the projection 27. Thus, the rubber band 26biases the door 22 in the clockwise direction as shown in FIG. 11.

As best shown in FIG. 2, the door 22 is partially cylindrical and ismounted in the cover 16, for rotation relative thereto about a generallyhorizontal axis 28, by oppositely extending projections 90 which extendalong the axis 28 and which are received in bores 92 in the cover 16.The door 22 has thereon a fin 34 which limits pivotal movement of thedoor 22 beyond the closed position (counterclockwise in FIG. 2) andwhich facilitates manual movement of the door 22 from the closedposition to the open position. Furthermore, the fin 34 allows the door22 to be opened with one hand holding an object, e.g., a hypodermicneedle, to be placed in the container 12.

The apparatus 10 further comprises means for preventing removal of thecontents of the container 12 when the door 22 is in the open position.While various suitable means can be employed, in the preferredembodiment, this means includes an integral baffle 36 on the door 22.When the door 22 is moved to the open position, the baffle 36 moves intoa position blocking the opening 24 in the cover 16, and the door 22 andbaffle 36 form an upwardly opening "cradle" into which an object can beplaced. The object is dumped out of the "cradle" and into the container12 when the door 22 returns to the closed position.

In order to prevent the escape of the contents of the container 12 whenthe container 12 is full, the apparatus 10 further comprises means forselectively and permanently locking the door 22 in the closed position.While various suitable means can be used, in the illustratedconstruction, such means includes an aperture 72 in the cover 16 and anaperture or recess 74 in the door 22. The locking means also includes apin 70 which extends through the aperture 72 and which is movablebetween a first or unlocked position wherein the pin 70 is removed fromthe recess 74 and a second or locked position wherein the pin 70 extendsinto the recess 74 when the door 22 is in the closed position.

The locking means also includes interengaging means on the pin 70 and onthe cover 16 for securing the pin 70 in the second or locked position.Preferably, as shown in FIGS. 10 and 13, the pin 70 has thereon twoaxially spaced sets of projections 80 which permit movement of the pin70 to the right as shown in the drawings or into the aperture 72 in thecover 16, but prevent movement of the pin 70 to the left or out of theaperture 72. When the pin 70 is in the unlocked position, as shown inFIG. 10, the pin 70 is only partially inserted into the aperture 72. Inthis position, the inner or right set of projections 80 engages thecover 16 to prevent outward movement of the pin 70, but the pin 70 doesnot extend into the recess 74 in the door 22. Thus, the door 22 is freeto pivot about the axis 28. The pin 70 is moved to the locked positionsimply by pushing the head of the pin 70 inwardly when the door 22 is inthe closed position. When the pin 70 is in the locked position, as shownin FIG. 13, the second or left set of projections 80 engages the cover16 to prevent outward movement of the pin 70, the inner end of the pin70 extends into the recess 74 to lock the door 22 in the closedposition, and the head of the pin 70 fits snugly into a recess orcounterbore 76 in the cover 16 so that the pin 70 is not removable onceit is fully inserted.

The apparatus 10 further comprises a bracket 44 adapted to be securelymounted on a wall by screws or other suitable means. Preferably, screws45 are inserted through apertures 46 in the bracket 44. The sides of thebracket 44 extend generally vertically and have thereon integral,forwardly offset tabs or projections 48. As shown in FIG. 6, the tabs 48converge slightly toward their upper ends.

The apparatus 10 further comprises interengaging means on the bracket 44and on the container 12 for securing the container 12 to the bracket 44.While various suitable means can be employed, in the preferredembodiment, such means includes, on the bracket 44, the tabs 48, and, onthe container 12, a pair of integral slots 50 positioned so as toslidably receive the tabs 48. As shown in FIG. 7, the slots 50 convergein the same manner as the tabs 48, so that the lower ends of the slots50 are slightly farther apart than are the upper ends of the tabs 48.The container 12 is mounted on the bracket 44 by holding the container12 above the bracket 44, aligning the slots 50 with the tabs 48, andlowering the container 12 onto the bracket 44 so that the tabs 48 slideinto the slots 50. Because the lower ends of the slots 50 are fartherapart than the upper ends of the tabs 48, it is easy to align the tabs48 and the slots 50. Downward movement of the container 12 relative tothe bracket 44 is limited by a lip 52 on the lower end of the bracket44.

The apparatus 10 further comprises means for preventing unauthorizedremoval of the container 12 from the bracket 44 and for permittingauthorized removal of the container 12 from the bracket 44. Whilevarious suitable means can be used, in the illustrated construction,this means includes a recess 54 in the rear wall of the container 12,and a pair of resilient, downwardly extending projections 56 on thebracket 44. The projections 56 are normally in a securing position (FIG.2) and are deflectible to a releasing position (FIG. 8). The projections56 are in the securing position and extend into the recess 54 when thecontainer 12 is secured on the bracket 44, so that the projections 56prevent upward movement of the container 12. The means for preventingunauthorized removal of the container 12 also includes key means fordeflecting the projections 56 from the securing position to thereleasing position. In the preferred embodiment, the key means includesa key 58 (FIGS. 8 and 9) having a pair of generally parallel, spacedapart prongs 60 which are insertable through apertures in the base 14and into engagement with the projections 56 for moving the projections56 from the securing position to the releasing position. When theprojections 56 are in the releasing position, the container 12 can bemoved upwardly relative to the bracket 44 and thus removed from thebracket 44.

An alternative embodiment of the invention is illustrated in FIGS.14-17. Except as explained hereinafter, the alternative embodiment issubstantially identical to the preferred embodiment, and common elementshave been given the same reference numerals.

In the alternative embodiment, the apparatus 10 comprises alternativemeans for selectively and permanently locking the door 22 in the closedposition, i.e., an alternative to the pin 70 of the preferredembodiment. More particularly, the means for selectively and permanentlylocking the door 22 in the closed position includes a slot 100 in thecover 16, and a projection or tab 102 which is pivotally mounted on thedoor 22 by a living hinge 103 and which is pivotally movable between afirst or unlocked position (FIGS. 14 and 15) wherein the projection 102does not extend into the slot 100 but extends generally coplanar withthe fin 34, and a second or locked position (FIGS. 16 and 17) whereinthe projection 102 extends into the slot 100 when the door 22 is in theclosed position. The locking means also includes interengaging means onthe projection 102 and on the cover 16 for securing the projection 102in the slot 100. While various suitable securing means can be employed,in the illustrated construction, the securing means includes atriangular, wedge-shaped tooth or protuberance 104 which extends fromthe underside of the projection 102, which facilitates insertion of theprojection 102 into the slot 100, and which, as shown in FIGS. 16 and17, engages the inside of the cover 16 when the projection 102 is fullyinserted into the slot 100 so that the projection 102 is not removablefrom the slot 100.

A second alternative embodiment of the invention is illustrated in FIGS.18-21. Except as explained hereinafter, the second alternativeembodiment is substantially identical to the preferred embodiment, andcommon elements have been given the same reference numerals.

In the second alternative embodiment, the container 12 includes a base14 and a separate cover 16. The container 12 also includes selectivelyinterengageable hinge means for pivotally connecting the cover 16 to thebase 14. While various suitable hinge means can be employed, in thesecond alternative embodiment, the hinge means includes a plurality ofspaced slots 110 located in the base 14 adjacent the upper, front edgeof the base 14, and a corresponding number of integral, spaced L-shapedprojections or teeth 112 located on the cover 16 adjacent the lower,front edge of the cover 16. Each of the teeth 112 includes (see FIG. 21)a first portion 114 extending inwardly and generally perpendicular tothe front wall 116 of the cover 16, and a second portion 118 extendinggenerally perpendicular to the first portion 114 and downwardly when thecover 16 is fully connected to the base 14. The first and secondportions 114 and 118 are connected by an integral arcuate portion 120having concentric inner and outer radii.

The cover 16 is connected to the base 14 by inserting the secondportions 118 of the teeth 112 into their respective slots 110, as shownin FIG. 19. The cover 16 is then rotated (counter-clockwise as shown inFIG. 19) relative to the base 14 until the first portions 114 of theteeth 112 are received in their respective slots 110 and the snapfasteners 20 secure the cover 16 in the closed position relative to thebase 14, as shown in FIG. 20. The inner and outer radii of the arcuateportions 120 of the teeth 112 facilitate insertion of the teeth 112 intothe slots 110 and rotation of the cover 16 relative to the base 14. Whenthe cover 16 is in the closed position relative to the base 14, thesecond portions 118 of the teeth 112 bear tightly against the inner faceof the front wall of the base 14. As shown in FIG. 21, the outer face ofthe base 14 has thereon a ridge or rabbet 122 that mates with the bottomedge of the front wall 116 of the cover 16 so that any needle that mightpenetrate the extremely small clearance between one of the teeth 112 andits respective slot 110 cannot extend through to the exterior of thecontainer 12.

The use of a cover 16 that is separate from the base 14 provides atleast two advantages. First, this permits the container 12 to beeconomically manufactured by multi-cavity molding. Second, this permitsa standard cover 16 to be used on containers 12 of varying sizes. With aseparate cover 16, the size of a container 12 can be varied simply byvarying the depth of the base 14.

Various features of the invention are set forth in the following claims.

We claim:
 1. A sharps container apparatus comprising a containerincluding a door manually movable between a closed position and an openposition, said container being completely closed when said door is insaid closed position, and a mechanism for selectively and permanentlylocking said door in said closed position, said locking mechanismincluding a recess in one of said container and said door, and aprojection which is pivotally connected to the other of said containerand said door by a living hinge for movement relative to said other ofsaid container and said door between a first position wherein saidprojection cannot be inserted into said recess regardless of theposition of said door and a second position wherein said projectionextends into said recess when said door is in said closed position. 2.Apparatus as set forth in claim 1 wherein said recess is a slot in saidcontainer.
 3. Apparatus as set forth in claim 1 wherein said lockingmechanism includes interengaging means on said projection and on saidone of said container and said door for securing said projection in saidsecond position.
 4. Apparatus as set forth in claim 3 wherein saidinterengaging means includes a wedge-shaped tooth located on saidprojection.
 5. Apparatus as set forth in claim 1 wherein said projectionis mounted on said door for pivotal movement between said first andsecond positions, and wherein said projection moves with said door assaid door moves between said open and closed positions.
 6. Apparatus asset forth in claim 1 wherein said projection can be inserted into saidrecess only after moving said projection relative to said other of saidcontainer and door without moving said door relative to said container.7. A sharps container apparatus comprising a container including a doormanually movable between a closed position and an open position, saidcontainer being completely closed when said door is in said closedposition, and a mechanism for selectively and permanently locking saiddoor in said closed position, said locking mechanism including a recessin one of said container and said door, and a projection which ispivotally connected to the other of said container and said door by aliving hinge for movement relative to said other of said container andsaid door between a first position wherein said projection is removedfrom said recess so that said door is unlocked when said door is in saidclosed position and a second position wherein said projection extendsinto said recess so that said door is locked when said door is in saidclosed position, such that a user can either lock said door in saidclosed position or leave said door unlocked when said door is in saidclosed position.
 8. Apparatus as set forth in claim 7 wherein saidrecess is a slot in said container.
 9. Apparatus as set forth in claim 7wherein said locking mechanism includes interengaging means on saidprojection and on said one of said container and said door for securingsaid projection in said second position.
 10. Apparatus as set forth inclaim 9 wherein said interengaging means includes a wedge-shaped toothlocated on said projection.
 11. Apparatus as set forth in claim 7wherein said projection is mounted on said door for pivotal movementbetween said first and second positions, and wherein said projectionmoves with said door as said door moves between said open and closedpositions.
 12. Apparatus as set forth in claim 7 wherein said projectioncan be inserted into said recess only after moving said projectionrelative to said other of said container and door without moving saiddoor relative to said container.
 13. Apparatus as set forth in claim 7wherein said door cannot be moved beyond said closed position in thedirection away from said open position.
 14. A sharps container apparatuscomprising a container including a door manually movable between aclosed position and an open position, said container being completelyclosed when said door is in said closed position, and a mechanism forselectively and permanently locking said door in said closed position,said locking mechanism including a recess in said container, and aprojection which is permanently located on said door, which moves withsaid door as said door moves between said open and closed positions andwhich is movable relative to said door between a first position whereinsaid projection cannot be inserted into said recess regardless of theposition of said door and a second position wherein said projectionextends into said recess when said door is in said closed position. 15.Apparatus as set forth in claim 14 wherein said recess is a slot in saidcontainer.
 16. Apparatus as set forth in claim 14 wherein said lockingmechanism includes interengaging means on said projection and on saidcontainer for securing said projection in said second position. 17.Apparatus as set forth in claim 16 wherein said interengaging meansincludes a wedge-shaped tooth located on said projection.
 18. Apparatusas set forth in claim 14 wherein said projection can be inserted intosaid recess only after moving said projection relative to said doorwithout moving said door relative to said container.
 19. A sharpscontainer apparatus comprising a container including a door manuallymovable between a closed position and an open position, said containerbeing completely closed when said door is in said closed position, and amechanism for selectively and permanently locking said door in saidclosed position, said locking mechanism including a recess in saidcontainer, and a projection which is permanently located on said door,which moves with said door as said door moves between said open andclosed positions and which is movable relative to said door between afirst position wherein said projection is removed from said recess sothat said door is unlocked when said door is in said closed position anda second position wherein said projection extends into said recess sothat said door is locked when said door is in said closed position, suchthat a user can either lock said door in said closed position or leavesaid door unlocked when said door is in said closed position. 20.Apparatus as set forth in claim 19 wherein said recess is a slot in saidcontainer.
 21. Apparatus as set forth in claim 19 wherein said lockingmechanism includes interengaging means on said projection and on saidcontainer for securing said projection in said second position. 22.Apparatus as set forth in claim 21 wherein said interengaging meansincludes a wedge-shaped tooth located on said projection.
 23. Apparatusas set forth in claim 19 wherein said projection can be inserted intosaid recess only after moving said projection relative to said doorwithout moving said door relative to said container.
 24. Apparatus asset forth in claim 19 wherein said door cannot be moved beyond saidclosed position in the direction away from said open position.